Grease (Not the
Musical)
You’re the one that I want….
Barbara Kanegsberg
It never fails. You think the cleaning process is totally under control only
to be faced with a series of inexplicable surface defects or product failures.
Yes, it could be the folks down the street spraying silicone-based materials.
As often as not, the problem can be traced to a lubricant used in your own
facility. Here are some tips to prevent critical cleaning and assembly problems
from lubricants and other metal working fluids.
Lubes and metalworking fluids are everywhere; they are essential to production.
However, undesirable residue from metalworking fluids can contribute to product
damage. Sudden poor performance of the critical or industrial cleaning process
is sometimes the first sign of trouble.
Has the metalworking fluid changed?
Check with the guys (or gals) in the machine shop. If there have been
obvious changes, you have a clue. Ask the operators why there has been
a change.
New lubes may be added to the shop floor for any of a number of reasons
such as:
Performance
Customer requirements
Environmental regulations
First, determine if these changes were due to actual versus perceived
requirements. Regulations are complex; and there can be honest misunderstandings.
In
addition, some enthusiastic sales reps can explain that a product
(typically a competing
product) is “banned” when it is merely slightly regulated.
Does the container look the same, but the contents are different?
If there are no stated changes, and container looks the same, ask
if the any of the lubes appear to have a different quality. A skilled
machinist will often be able to detect subtle changes.
You may have to contact the supplier to determine why a change
has been made and whether or not an equivalent product can be
obtained.
Cost, supply chain, arbitrary “bean counter” activities
Sometimes, the shop orders one process chemical; but the Purchasing
or Procurement group sends something else. “Bean counters” are
trying to save your company money, so be kind to them.
However, if the new product is impacting performance, let Purchasing
know. Get them to help fix the problem. If they explain how
much less the new lube
will cost, you can explain how much money will have to be
spent on a new cleaning process.
Head off future headaches
If the lube change is necessary, the only solution may be
to modify the cleaning process, because when the soil changes,
the cleaning
process often has to
change along with it.
To maximize profits and avoid product defects, if there
is any change in the assembly or repair process, there
really
has to
be a system
for:
Advance notification
Communication
This includes not only changes in product design but
also changes in any process or process chemistry;
and metalworking
fluids
are chemicals.
If you
are the boss, or if you are in change of the paperwork,
start requiring change notifications from:
Production
Purchasing
Engineering
Outside suppliers
If you are not in charge but are only vexed by the
hassle of unexpected changes and product defect,
consider passing
this
article along
to the right person.
Coming soon: Grease II (True Grit)
